Covestro and Fraunhofer UMSICHT have signed a contract to build a pilot plant in Germany that will use smart pyrolysis to convert rigid polyurethane (PU) foam waste into high-purity aniline for methylene diphenyl diisocyanate (MDI) production. The facility, with an annual capacity of 2,000 tonnes, is set to begin operations in mid-2028 and targets up to a 40% reduction in the carbon footprint compared to conventional, fossil-based production methods. The pilot, located at Fraunhofer UMSICHT's site in Sulzbach-Rosenberg, will address the recycling challenge posed by rigid PU/PIR foam's crosslinked molecular structure.Covestro and Fraunhofer UMSICHT have signed a contract to operate a 2 kt per year pilot plant for smart pyrolysis of rigid polyurethane foam waste{{cite:}} The plant is scheduled to begin operations in mid-2028{{cite:}} Resulting MDI has up to 40 percent lower carbon footprint compared to conventional fossil-based production routes{{cite:}} The pilot will produce high-purity recycled aniline suitable for MDI production{{cite:}}
Background
Rigid polyurethane (PUR/PIR) foam waste is difficult to recycle because of its highly crosslinked polymer network. Chemical recycling through pyrolysis breaks molecular bonds, enabling recovery of aniline, a critical feedstock for MDI used in insulation and refrigeration applications. The pilot plant builds on years of joint research by Covestro and Fraunhofer UMSICHT, including laboratory and mini-plant testing within the EU-funded CIRCULAR FOAM project.The technology builds on extensive research within CIRCULAR FOAM, an EU-funded flagship project coordinated by Covestro with Fraunhofer UMSICHT and 23 other partners across Europe{{cite:}}
Details
The facility is designed to process around 2,000 tonnes of end-of-life rigid foam annually. The recovered aniline could produce enough MDI for the insulation in approximately 200,000 refrigerators each year.The pilot plant has an annual capacity to recycle 2 kt of end-of-life foam per year{{cite:}} The resulting amount of aniline could be used to produce insulation for roughly 200,000 refrigerators{{cite:}}
Dr. Markus Dugal, Covestro's Head of Process Technology, stated the contract is a decisive step toward industrializing smart pyrolysis, combining Covestro's chemical expertise with Fraunhofer's process engineering capabilities. He noted the significance of recovering high-value molecules from waste for advancing circular economy goals and reducing carbon emissions. Professor Dr. Ing. Manfred Renner, Head of Fraunhofer UMSICHT, said the project demonstrates the institute's commitment to translating research into industrial applications. Dr. Alexander Hofmann, Head of Thermochemical Conversion Technologies at Fraunhofer UMSICHT, emphasized that the pilot plant will facilitate process optimization at scale and provide material for further processing and market trials."The contract with Fraunhofer UMSICHT is a decisive step towards industrializing our smart pyrolysis technology," said Dr. Markus Dugal, Head of Process Technology of Covestro{{cite:}} "This project represents the culmination of several years of intensive joint research," explains Prof. Dr.-Ing. Manfred Renner, Head of Institute Fraunhofer UMSICHT{{cite:}} "The pilot plant will allow us to optimize process parameters at scale and provide sufficient material for further processing tests and market development," said Dr. Alexander Hofmann, Head of Thermochemical Conversion Technologies at Fraunhofer UMSICHT{{cite:}}
The smart pyrolysis process produces aniline with about 99% purity, matching the quality of conventional MDI feedstock. The European MDI market for rigid foam is expected to increase from 1,400 kilotonnes in 2025 to 1,900 kt by 2035, driven by higher demand for energy-efficient building and refrigeration insulation. Regulatory requirements in the EU are also driving the need for scalable, end-of-life solutions for rigid PUR/PIR foam.The smart pyrolysis process yields aniline with approximately 99 percent purity{{cite:}} The MDI market for rigid foam is projected to grow from 1,400 kt in 2025 to 1,900 kt in 2035 in Europe{{cite:}}
Outlook
If successful, the pilot will support scaling of smart pyrolysis for industrial use, enabling closed-loop recycling of rigid PU foam and reducing the carbon footprint of MDI production. This approach could also support compliance with evolving EU regulations and further circular economy objectives across the polymer and insulation sectors.
